Adjustable air bypass system for heating appliance

ABSTRACT

An air bypass system for use with a heating appliance that includes an outer enclosure and a combustion chamber enclosure positioned within the outer enclosure. The bypass system includes a first opening providing an air passage between a source of air from a remote location and an air space defined between the outer enclosure and the combustion chamber enclosure. The bypass system also includes a second opening providing an air passage between a source of room air and the air space, and an actuating member configured for movement between a first position substantially covering the first opening wherein the second opening is open for air flow, and a second position substantially covering the second opening wherein the first opening is open for air flow.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to heating appliances, and more specifically relates to air control systems for heating appliances.

2. Related Art

Many heating appliances include an air circulation system that draws in cool air into or around the source of heat thereby heating the cool air, and then exhausts the heated air to a targeted area. The cool air is typically drawn from one of several sources: a local living space in which the heating appliance resides, a remote living space, or a space outside the building that houses the heating appliance. One advantage of using the targeted living space as a source of cool air is that the cool air in that particular space is removed from the room by being drawn from a lower part of the living space into the heating appliance. The cool air can then be replaced with warmer air. Similarly, drawing cool air from a lower portion of a remote living space removes the cool air from that remote space so that warm air can replace the removed cool air.

A disadvantage of using the living spaces of a building as a source of cool air is that a vacuum condition may result, which may result in cool air from outside the building being drawn into the building through the many small cracks and openings that are common in almost all buildings. The cool outside air leaking into the building then typically settles downward in the living space because it is more dense than the warm air in the building, and moves toward the cool air inlet for heating appliance causing a “draft” condition throughout the building.

Using outside air as a source of cool air also has some advantages. One such advantage is that fresh, typically clean air is brought into the building in a controlled way. Another advantage of using outside air is that the air drawn in from outside the building creates an overpressure condition in the building that forces the stale air out of the small cracks and openings of the building, which in turn prevents cool air from leaking into the building through those same small cracks and openings in an uncontrolled manner.

Most known heating appliances include one of the air control systems discussed above. Once a heating appliance with one of these air control systems is installed there are limited alternatives for the source of cool air besides the single source provided by the system.

SUMMARY OF THE INVENTION

The present invention relates to heating appliances and air control systems for heating appliances. More specifically, the present invention relates to an air bypass system for a heating appliance such as a wood stove or fireplace, which controls whether air being heated in an air space around the heat source (e.g., around a combustion chamber enclosure) is provided from a remote location or from the room in which the heating appliance resides.

One aspect of the present invention relates to an air bypass system for use with a heating appliance that includes an outer enclosure and a combustion chamber enclosure positioned within the outer enclosure. The bypass system includes a first opening providing an air passage between a source of air from a remote location and an air space defined between the outer enclosure and the combustion chamber enclosure. The bypass system also includes a second opening providing an air passage between a source of room air and the air space, and an actuating member configured for movement between a first position substantially covering the first opening wherein the second opening is open for air flow, and a second position substantially covering the second opening wherein the first opening is open for air flow.

Another aspect of the present invention relates to a method of controlling air flow in a heating applicant that includes an adjustable member, an outer enclosure, and a combustion chamber enclosure positioned within the outer enclosure. The heating appliance includes an air space defined between the outer enclosure and the combustion chamber enclosure. The method includes providing a first opening between the air space and a source of air from a remote location, and a second opening between the air space and a source of room air. The method further includes moving the adjustable member between a first position wherein the first opening is substantially covered by the adjustable member and the second opening is left open for the flow of remote air into the air space, and a second position wherein the second opening is substantially covered by the adjustable member and the first opening is left open for the flow of room air into the air space.

A yet further aspect of the invention relates to an air bypass system that includes a housing member having first and second chambers, and an adjustable cover. The first chamber includes a first air inlet opening and a first air outlet opening, and the first chamber is in fluid communication with a source of air from a remote location. The second chamber includes a second air inlet opening and a second air outlet opening, and the second chamber is in fluid communication with a source of local air. The adjustable cover is movable between a first position substantially shutting off air flow through the first chamber, wherein the second chamber is left open for the flow of remote air through the second air inlet and outlet openings, and a second position substantially shutting off air flow through the second chamber, wherein the first chamber is left open for the flow of local air through the first air inlet and outlet openings.

The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The Figures and the detailed description that follow more particularly exemplify embodiments of the invention. While certain embodiment of the invention will be illustrated in describing embodiments of the invention, the invention is not limited to use in such embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

FIG. 1 is a front plan view of a wood stove assembly that includes an example air bypass system according to principles of the invention;

FIG. 2 is a top plan view of the wood stove assembly shown in FIG. 1 with a top panel of the wood stove outer enclosure removed;

FIG. 3 is a side plan view of the wood stove assembly shown in FIG. 1 with a side panel of the wood stove outer enclosure removed;

FIG. 4 is an exploded front perspective view of the wood stove assembly shown in FIG. 1;

FIG. 5 is a top plan view of the example air bypass system shown in FIG. 1-3;

FIG. 6 is a front plan view of the example air bypass system shown in FIG. 1-3;

FIG. 7 is a side plan view of the example air bypass system shown in FIG. 1-3;

FIG. 8 is an exploded front perspective view of the air bypass system shown in FIGS. 1-3;

FIG. 9A is a front perspective view of the air bypass system shown in FIGS. 1-3 with flow lines indicating air flow through a left side chamber of the air bypass system;

FIG. 9B is a front perspective view of an example wood stove assembly illustrating air flow into and out of the wood stove assembly when the air bypass system is set as shown in FIG. 9A;

FIG. 10A is a front perspective view of the air bypass system shown in FIGS. 1-3 with flow lines indicating air flow through a right side chamber of the air bypass system;

FIG. 10B is a front perspective view of an example wood stove assembly illustrating air flow into and out of the wood stove assembly when the air bypass system is set as shown in FIG. 10A;

FIG. 11 is a front perspective view of another example air bypass system that includes a rotatable cover; and

FIG. 12 is a front cross-sectional view of the air bypass system shown in FIG. 11 taken along cross-sectional indicators 12-12.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention relates to an air bypass system for a heating appliance such as a wood stove, which controls whether air being heated in an air space around the heat source of the heating appliance (e.g., around a combustion chamber enclosure of a wood stove) is provided from a remote location or from the room in which the heating appliance resides.

The heating appliances disclosed and illustrated herein for use with the air bypass system of the present invention are wood stoves. However, the air bypass system of the present invention may be used with other heating appliances, such as, for example, gas fireplaces, electric fireplaces, heaters, furnaces, or other heating appliances that require control of air to a space around the heat source. Some example fireplaces that may be used in conjunction with the air bypass system of the present invention include a direct vent, a universal vent, a B-vent, a horizontal/vertical-vent, a dual direct vent, and a multisided unit having two or three glass panels as combustion chamber side panels. While the present invention is not so limited, an appreciation of various aspects of the invention will be gained through a discussion of the examples provided below.

As used herein, a “combustion chamber” may include any structure that at least partially encloses a space in which a flame is generated from combusting material, solid or gas, simulating a flame, or otherwise producing heat. An “outer enclosure” is defined as any structure of a heating appliance surrounding the combustion chamber enclosure. The terms “outside air”, “fresh air”, and “remote air” generally refer to air supplied from a location outside a living space in which the heating appliance resides. The terms “room air” and “local air” generally refer to air supplied from the living space in which the heating appliance resides.

Referring now to FIGS. 1-3 a wood stove assembly 10 suited for use with an air bypass system 16 of the present invention is shown and described. Wood stove assembly 10 includes an outer enclosure 12, a combustion chamber enclosure 14, and an air bypass system 16 positioned between the outer enclosure 12 and the combustion chamber enclosure 14. The wood stove assembly 10 also includes first and second pairs of blowers 18, 19, a combustion air channel 22, a side air retention panel 24, first and second side air diverter panels 26, 28, and a front air retention panel 30.

The channels and panels listed above direct fresh combustion air from a combustion air inlet 56 into the combustion chamber enclosure 14, and direct air from a remote location through a remote air inlet 58 into the air bypass system 16 and into a space 13 between the outer enclosure 12 and combustion chamber enclosure 14. The space 13 provides an air insulation barrier between a heated combustion chamber enclosure 14 and the outer enclosure 12.

The outer enclosure 12 includes top and bottom panels 40, 42, front and rear panels 44, 46, and first and second side panels 48, 50. A vent pipe opening 52 is formed in the top panel and a vent pipe flange 54 associated with opening 52 may be used to couple an exhaust vent pipe to the wood stove assembly 10. In some types of heating appliances, such as a direct vent fireplace, fresh combustion air for combustion in the combustion chamber 14 may be provided coaxially with the exhaust vent pipe of the heating appliance rather than using a separate co-lineal pipe as shown in FIGS. 1-4 with the exhaust vent pipe to a separate location on the heating appliance such as combustion air inlet 56 shown in FIGS. 1-4.

The outer enclosure 12 defines an inner volume sized to receive the combustion chamber enclosure 14, and includes top and bottom panels 70, 72, front and rear panels 74, 76, and first and second side panels 78, 80 that together define a combustion chamber 84. Typically, a combustion air inlet 82 is formed in the bottom panel 72 or at other targeted areas in the combustion chamber enclosure 14 to provide fresh combustion air at required locations within combustion chamber 84.

The combustion chamber 84 may be used to contain any type of heat generation common in the art such, as for example, combustion of solid fuel such as wood, wood pellets, corn, etc., combustion of gas, and electric heat generation. The air bypass system of the present invention is generic to any heating appliance since it deals primarily with heat recovery around the combustion chamber enclosure rather than fluid flow within the combustion chamber enclosure.

Referring now to FIGS. 5-8, the air bypass system 16 includes top and bottom panels 100, 102, front and rear panels 104, 106, and a dividing panel 108. A first inlet opening 110 is formed in the front panel 104 and a second inlet opening 12 is formed in a first side 109 of the air bypass system 16. The panels of the system define first and second air chambers 111, 113. First and second outlet openings 114, 116 provide an air outlet from respective first and second air chambers 111, 113.

Air bypass system 16 further includes first and second track members 118, 120, a cover 122, a mounting bracket 124, and an adjustment arm 126. The adjustment arm 126 includes first and second ends 128, 130, a slot 132, and a pivot point 134. The cover 122 is retained between first and second track members 118, 120 so as to be movable in the plane of top panel 100 between a first position covering the first outlet opening 114, and a second position covering second outlet opening 116. The first end 128 of adjustment arm 126 is coupled to the cover 122 via a fastener that moves in slot 132. The slot 132 allows linear motion of cover 122 when actuated by the pivotal movement of adjustment arm 126 about pivot point 134. The second end 130 of adjustment arm 126 extends out beyond the front panel 144 of the outer enclosure 12 for easy access by a user. The second end 130 is movable in the direction D to move cover 122 into the second position, and is movable in the opposite direction E to move the cover 122 into the first position (See FIG. 5).

Although the cover 122 is shown in FIGS. 5-8 as being slidably movable in a single plane between first and second positions, alternative designs may be used to provide the desired opening and closing of the air outlets from the air bypass system 16. Referring now to FIGS. 11 and 12 and air bypass system 300 that includes an alternative cover design is shown and described. Air bypass system 300 includes a top panel 302, a front panel 304, a center panel 306, first and second inlet openings 310, 312, and first and second outlet openings 314, 316, which substantially match the features of air bypass system 16. System 300 further includes first and second cover members 321, 322 coupled to an adjustment arm 326 that is rotatable about an axis that extends perpendicular to the plane of the front panel 304. By rotating the adjustment arm 326 in the direction F, the panels 321, 322 move between the first position 330 (shown in phantom) wherein the first opening 314 is covered and the opening 316 is open, and the second position 332 (shown with solid lines) wherein the second opening 316 is covered and the first opening 314 is open. This “butterfly” style design may further include a biasing member that helps hold the cover members 321, 322 in the first or second position, or some position there between.

Holding the cover members 321, 322 (or the cover member 122 described above) in a position between the first and second positions may have certain advantages such as, for example, providing a limited source of fresh air into the living space and pressurizing the living space under certain conditions.

Referring now to FIGS. 9A, B and 10A, B, the air bypass system 16 is described in further detail with reference to its function relative to a wood stove assembly 200 (FIGS. 9B, 10B). The wood stove assembly 200 includes a room air inlet opening 202, an exhaust opening 204, and a remote air inlet opening 158. The openings 158, 202 are in fluid communication with the air bypass system 16 and the exhaust opening 204 is in fluid communication with the space 13 between the combustion chamber enclosure and outer enclosure of the wood stove assembly 200.

Referring first to FIGS. 9A and 9B, when the cover 122 is moved in a direction D by adjustment arm 126 so as to cover a second outlet opening 116, room air moves as air flow A through the first inlet opening 110, the first air chamber 111 and the first outlet opening 114, and later exhausted out exhaust opening 204 as heated exhaust air flow B.

Referring now to FIGS. 10A and 10B, when the cover 122 is moved in a direction E by adjustment arm 126 to cover a second outlet opening 118, remote air moves as air flow C through the remote air inlet opening 158, the second inlet opening 112, the second air chamber 113, and the second outlet opening 116, and is exhausted as exhaust air flow B from the exhaust opening 204.

The air bypass system 16 provides the advantage of controlling the source of air being heated within a wood stove assembly between the combustion chamber enclosure and the outer enclosure depending on the needs of the user and the heating requirements of the living structure in which the wood stove assembly resides. For example, if some areas of the living structure are colder than others (such as a basement room), air may be drawn from that particular room in the living structure and provided as the source of remote air supplied to the air bypass system, while warmer air is replaced in the room where the remote air is drawn. In another example, the source of remote air may be outside the living structure so as to provide fresh air into the living structure and create a desired pressure conditioned within the living structure. In a yet further example, the air bypass system may be adjusted so that room air is heated by the wood stove assembly rather than air from a remote source.

Another air bypass system (not shown) may control air flow between the space around the combustion chamber enclosure and three or more sources of air. For example, the air bypass system may include three separate air chambers that are connected separately to a remote source of air and two local sources of air, or to three remote sources of air. An air bypass system with three or more separate sources of air may be configured so that one, two or all of the air sources provide air to the space around the heat source of the heating appliance at any given time.

The air bypass system illustrated in the Figures discloses a cover member(s) that provides opening of one air outlet while the other air outlet from the bypass system is being closed. Although the examples disclosed herein may provide for partial opening of both air outlets, a configuration in which both air outlets are fully open is not shown. It is envisioned that other embodiments may include features that individually control air flow through each air outlet of the air bypass system, whether there are two, three or more air outlets corresponding to separate sources of air in fluid communication with the air bypass system. With such individual control of the air outlets, all or some of the air outlets may be opened or closed simultaneously.

Air flow through the air outlets of the air bypass system may be controlled with any of a variety of control mechanisms and devices such as, for example, the slideable cover shown in FIGS. 2-10A, the butterfly covers shown in FIGS. 11 and 12, magnetic devices, solenoids, and stepper motors. The control mechanisms useful for the present invention may be controlled through various manual and electronic devices, such as, for example, a microprocessor, an electronic timer, radiofrequency, or a manual adjustment arm.

Although the figures described above illustrate exhaustion of the heated air out of the wood stove assembly directly back into the living space in which the wood stove assembly resides, other embodiments may be configured to direct the heated air to a heat recovery system, such as the systems disclosed in U.S. Pat. No. 6,550,687, U.S. patent application Ser. No. 10/339,739 filed on Jan. 8, 2003 and entitled HEAT EXCHANGE SYSTEM, and U.S. patent application Ser. No. 10/371,761 filed on Feb. 24, 2003 and entitled FIREPLACE MAKEUP AIR HEAT EXCHANGE SYSTEM, which issued patent and patent applications are incorporated herein by reference. The heated air produced may also be directed to various places within the living structure as disclosed in U.S. Pat. No. 6,019,099, which is also incorporated herein by reference.

A method according to principles of the present invention may be directed to controlling air flow in a heating appliance that includes an adjustable member, an outer enclosure, and a combustion chamber enclosure positioned within an outer enclosure so as to define an air space between the outer enclosure and the combustion chamber enclosure. The method may include steps of providing a first opening between the air space and a source of air from a remote location, and a second opening between the air space and a source of room air, and moving the adjustable member between a first position wherein the first opening is substantially covered by the adjustable member and a second opening is left open for the flow of remote air into the air space, and a second position wherein the second opening is substantially covered by the adjustable member and the first opening is left open for the flow of room into the air space.

The heating appliance of the method may further include an air bypass system that includes a housing having first and second air chambers, the first air chamber including the first opening and the second air chamber including the second opening, and the first chamber is in fluent communication with the remote air and the second chamber is in fluent communication with the room air. Another step of the method may include heating air in the air space by moving the air around the combustion chamber enclosure and exhausting the heated air out of the outer enclosure. The adjustable member of the heating appliance may include a movable cover, and the moving step includes sliding the cover between the first and second positions or rotating the cover between the first and second positions. A yet further step of the method may include positioning the air bypass system vertically below the combustion chamber enclosure.

The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification. 

1. An air bypass system for use with a heating appliance that includes an outer enclosure and a combustion chamber enclosure positioned within the outer enclosure, the bypass system comprising: a first opening providing an air passage between a source of air from a remote location and an air space defined between the outer enclosure and the combustion chamber enclosure; a second opening providing an air passage between a source of room air and the air space; an actuating member configured to control opening and closing of the first and second openings.
 2. The system of claim 1, wherein the actuating member is movable between a first position covering the first opening wherein the second opening is open for air flow, and a second position substantially covering the second opening wherein the first opening is open for air flow.
 3. The system of claim 1, further comprising a housing member having first and second air chambers, the first chamber including the first opening and a first inlet opening in fluid communication with the source of remote air, the second chamber including the second opening and a second inlet opening in fluid communication with the source of room air.
 4. The system of claim 1, wherein the actuating member includes a cover member configured to shut off air flow through the first opening or the second opening, and an actuating arm coupled to the cover member to move the cover member.
 5. A method of controlling air flow in a heating appliance that includes an adjustable member, an outer enclosure, and a combustion chamber enclosure positioned within the outer enclosure, an air space being defined between the outer enclosure and the combustion chamber enclosure, the method comprising the steps of: providing a first opening between the air space and a source of air from a remote location, and a second opening between the air space and a source of room air; and moving the adjustable member to control air flow out of the first and second openings and into the air space between the outer enclosure and the combustion chamber enclosure.
 6. The method of claim 5, wherein the adjustable member includes a cover, and the moving step includes moving the cover between a first position wherein the first opening is substantially covered by the cover and the second opening is left open for the flow of remote air into the air space, and a second position wherein the second opening is substantially covered by the cover and the first opening is left open for the flow of room air into the air space
 7. The method of claim 5, wherein the heating appliance further includes an air bypass system that includes a housing having first and second air chambers, the first air chamber including the first opening, and the second air chamber including the second opening, and the first chamber is in fluid communication with the remote air and the second chamber is in fluid communication with the room air.
 8. The method of claim 5, further comprising heating air in the air space by moving the air around the combustion chamber enclosure and exhausting the heated air out of the outer enclosure.
 9. The method of claim 6, wherein the moving step includes sliding the cover between the first and second positions.
 10. The method of claim 6, wherein the moving step includes rotating the cover between the first and second positions.
 11. The method of claim 5, further comprising the step of positioning the air bypass system vertically below the combustion chamber enclosure.
 12. An air bypass system, comprising: a housing member including first and second chambers, the first chamber including a first air inlet opening and a first air outlet opening and being in fluid communication with a source of air from a remote location, the second chamber including a second air inlet opening and a second air outlet opening and being in fluid communication with a source of local air; and an adjustable cover movable between a first position substantially shutting off air flow through the first chamber wherein the second chamber is left open for the flow of remote air through the second air inlet and outlet openings, and a second position substantially shutting off air flow through the second chamber wherein the first chamber is left open for the flow of local air through the first air inlet and outlet openings.
 13. The system of claim 12, further comprising an adjusting arm coupled to the adjustable cover and configured to move the adjustable cover between the first and second positions.
 14. The system of claim 12, wherein the adjustable cover rotates between the first and second positions.
 15. The system of claim 12, wherein the adjustable cover moves laterally between the first and second positions.
 16. An air control system for controlling air available to a space around a heat source of a heating appliance, the system including a first air passage in fluid communication with a first source of air and the space, and a second air passage in fluid communication with a second source of air and the space, and including actuating means configured to control air flow through the first and second air passages. 